Safety System for workers in freezer room Bachelor Thesis for Optimar AS

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(1)Graduate thesis. Daniel Erichsen Shajeevan Panchardcharam Eilev Brustugun. Safety System for workers in freezer room Bachelor Thesis for Optimar AS Graduate thesis in Automatiseringsteknikk. NTNU Norwegian University of Science and Technology Faculty of Information Technology and Electrical Engineering Department of ICT and Natural Sciences. Supervisor: Kjell Inge Tomren, Ottar Osen May 2020.

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(3) Daniel Erichsen Shajeevan Panchardcharam Eilev Brustugun. Safety System for workers in freezer room Bachelor Thesis for Optimar AS. Bachelor’s project in Automatiseringsteknikk Supervisor: Kjell Inge Tomren, Ottar Osen May 2020 Norwegian University of Science and Technology Faculty of Information Technology and Electrical Engineering Department of ICT and Natural Sciences.

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(5) Safety System for workers in freezer room Bachelor Thesis for Optimar AS. Daniel Erichsen, Eilev Brustugun, Shajeevan Panchardcharam. A thesis presented for the degree of Bachelor in Automation IE303612. Faculty of Information Technology and Electrical Engineering Norwegian University of Science and Technology Norway 09.01.20 - 20.05.20.

(6) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Mandatory self declaration/ group declaration Every group member is responsible for familiarizing himself with the legal aids, guidelines for their use of sources. This statement should make the group members aware of their responsibilities and what consequences that can occur if cheating takes place. You fill out the declaration by clicking in the box to the right of each section 1-6:. 1. 2.. 3.. 4. 5. 6.. I/We hereby declare that my/our answer is my/our own work, and that I/we have not used any other sources or received any help other than that mentioned in the answer I/We declare that this reply: • has not been used for another exam at another department/university/university college or abroad • does not refer to the work of others without being stated • does not refer to own previous work without it being stated • has all the references listed in the literature list • is not a copy, duplicate or copy of the work or response of others. . I / We are aware that violations of the above are regarded as cheating and may result in the cancellation of examinations and exclusion from universities and colleges in Norway, jf. Universitests- og høgskoleloven §§4-7 og 4-8 og Forskrift om eksamen §§14 og 15 I / We are aware that all submitted assignments can be plagiarized in Ephorus, see Guidelines for electronic submission and publication of credits for studio assignments I / we are aware that ntnu university will handle all cases where there is suspicion of cheating according to the university’s study regulations I / we have familiarized ourselves with the rules and guidelines in the use of source and references on the library’s website. . Table 1: Mandatory self declaration. i. . . .

(7) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Publishing Agreement Number of credits: 20 Supervisors: Kjell Inge Tomren, Ottar L. Osen. Authorization for electronic publication of the thesis Author(s) have copyright on the thesis. This means, among other things, the exclusive right to make the work accessible to the general public (Åndsverksloven §2). All papers that fulfill the criteria will be registered and published in Brage HiM with the author(s) approval. Tasks that are except public or tape-free will not be published.. I/we hereby grant NTNU in Aalesund a free right to make the thesis available for electronic publishing: Is the assignment pledged (confidential)? (Placement agreement must be completed) - If Yes: Can the thesis be published when the bonding period is over? Is the assignment except the public? (Contains confidential information. Jfr. Offl. §13/Fvl. §13). Date: 20.03.2020 Table 2: Publishing agreement. ii. YES. 2 . NO. . YES. . 2 . YES. . NO. . 2 . NO. . YES. NO.

(8) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Preface Health, safety and environment is a concept that includes most peoples involvement in today’s working life. Optimar in Aalesund seeks to optimize the safety of all workers using their fish handling equipment. During a fatal accident at the trawler Geir II, Optimar discovered the lack of accessibility to contact critical personnel. One area where the environment is harsh and safety is lacking, is inside freezer rooms. This thesis elaborates the development of a safety system for workers inside freezer rooms, with the intention to minimize the outcome of injuries happening inside these freezers. The bachelor thesis is a result of a collaboration between students at NTNU Aalesund and the fish handling company Optimar AS. The project is a part of the bachelor program in electrical engineering, with specialization in automation, at the Faculty of Information Technology and Electronics. The report is written and prepared by a group of students with different backgrounds. Two students with a certificate of apprenticeship, one in automation and one in data electronics, the last member having a theoretical background from high school. We inform the reader of this thesis, that the report is written with the intention that the reader has the general understanding of the subjects engineering and automation.. iii.

(9) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Acknowledgment We would like to thank our supervisors, and all our contributors who have helped us during this project: ò Kjell Inge Tomren - Professor, NTNU For contributing very useful and essential information for the task, as well as valuable data for several of our analyzes. ò Ottar Osen - First Associate Professor, NTNU For guidance throughout the project and also contributing very useful and essential information for the task. ò Åge Molnes - Automation Team Manager, Optimar AS For making the collaboration possible ò Robert Johnsen - Senior Automation Engineer, Optimar AS For guidance throughout the project ò Richard Giske - Group Leader Programming, Optimar AS For advice’s and tips for the programming of GUI ò Joakim Andersson - Project Manager, Tele-Radio For guidance arround communication for the handheld transmitter and receiver ò Thomas Sørheim Egge - Production Engineer, Tele-Radio For programming the handheld transmitter as desired. iv.

(10) Eilev Brustugun. Shajeevan Panchardcharam. Daniel Erichsen. Sted: Aalesund. Dato: 20.05.2020 v.

(11) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Acronyms PLC. Programmable logic controller. HMI. Human Machine Interface. IP. Internet protocol. LAN. Local area network. CCTV. Closed-circuit television. WLAN. Wireless local area network. PC. Personal Computer. GUI. Graphical User Interface. LED. Light Emitting Diode. IP-rating. International Protection. DI. Digital Input. DO. Digital Output. OS. Operating system. LD. Ladder Diagram. SFC. Sequential Function Charts. FBD. Function Block Diagram. ST. Structured Text. IL. Instruction List. vi.

(12) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Terminology PLC. Logical controller used in the industry to control machinery, sensors and similar. PLC modules. Additional modules that can be added to PLC for more functionality: • Power Supply Module: Module used to supply other modules with power, makes it possible to have different power supplies for different modules. • I/O-Module: Module for PLC consisting of input and/or outputs. Could be either analog, digital or both.. EX-area. Explosion Hazardous Areas. The areas are divided into three zones for gas: Zone 0, Zone1 and Zone2, and three corresponding zones for dust: Zone 20, Zone 21 and Zone 22. Where zone 0 and 20 are high risk and 2 and 22 are low or non risk.. NPN and PNP output NPN outputs a zero voltage signal. When an output gets triggered it will connect the output to the negative supply. PNP outputs a positive voltage signal. When an output gets triggered it will connect the output to the positive supply.[13]. vii.

(13) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Executive Summary The intention of the thesis is to develop a field leading safety system for freezer rooms in fishing vessels. The system must be capable of being mounted in the new fishing vessel Geir III, and to the same extent retrofitted in existing fishing vessels. The safety system aims to minimize the outcome of accidents and be life saving, with a minimal effect to the work flow. On the 30th September 2010 a fatal accident happened to one of the workers of the trawler, Geir II. Optimar was one of the core suppliers delivering equipment for fish handling to Geir II. During this accident Optimar discovered the lack of safety for workers working alone in the large freezer compartment of Geir II. Optimar is currently in the process of delivering equipment to a new version of Geir II, Geir III. One of the goals of this new vessel is to improve the safety of the workers. The approach of the thesis is to build a prototype that would serve as a concept of the finalized product being implemented in Geir III. The aim of the prototype is to prove that such a safety system can become a commercial product for Optimar. The result of the prototype left us confident that the safety system can be a commercial product for the fishing industry, and contribute to minimizing the severity of accidents. The prototype complies with the standards set by Optimar, and is designed with scalability and versatility in mind. Making it possible for the safety system to be implemented in new vessels or retrofitted in older vessels, without any major modifications.. viii.

(14) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Contents Mandatory self declaration/ group declaration. i. Preface. iii. Acknowledgement. iv. Acronyms and Terminology. vi. Executive Summary. viii. 1 Introduction. 1. 1.1. Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1. 1.2. Project introduction . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2. 1.3. Bachelor degree specification . . . . . . . . . . . . . . . . . . . . . . .. 2. 1.4. Collaboration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3. 1.5. Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3. 1.6. Aim and objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4. 1.7. Long term goals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4. 1.8. Report Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5. 2 Theoretical Basis and Background. 6. 2.1. Fishing vessels and fish handling . . . . . . . . . . . . . . . . . . . . .. 6. 2.2. Geir III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7. 2.3. Freezer room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8. 2.3.1. Working inside a freezer . . . . . . . . . . . . . . . . . . . . .. 8. Industrial Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10. 2.4.1. Programmable Logical Controller . . . . . . . . . . . . . . . .. 10. 2.4.2. Human-Machine Interface . . . . . . . . . . . . . . . . . . . .. 12. Graphical user interface (GUI) . . . . . . . . . . . . . . . . . . . . . .. 14. 2.5.1. Industrial Remote controls . . . . . . . . . . . . . . . . . . . .. 15. Communication protocols . . . . . . . . . . . . . . . . . . . . . . . .. 15. 2.6.1. Ethernet- protocol . . . . . . . . . . . . . . . . . . . . . . . .. 15. 2.6.2. Ethernet/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15. 2.7. Maritime electrical installation . . . . . . . . . . . . . . . . . . . . . .. 16. 2.8. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16. 2.4. 2.5 2.6. ix.

(15) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.9. Report. HMI Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17. 2.9.1. Background Color . . . . . . . . . . . . . . . . . . . . . . . . .. 17. 2.9.2. Color Choice For Objects. . . . . . . . . . . . . . . . . . . . .. 18. 2.9.3. Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18. 2.9.4. Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18. 2.9.5. Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19. 3 Approach. 20. 3.1. Approach due to the Covid-19 . . . . . . . . . . . . . . . . . . . . . .. 20. 3.2. Project organization . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20. 3.3. Project description . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21. 3.3.1. Specifying main description . . . . . . . . . . . . . . . . . . .. 22. 3.3.2. Brainstorming functions . . . . . . . . . . . . . . . . . . . . .. 23. 3.3.3. Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24. 3.3.4. Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26. 3.3.5. Prototype . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27. 3.4. Reviews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27. 3.5. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28. 3.5.1. HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28. 3.5.2. PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28. 3.5.3. Handheld transmitter and receiver. . . . . . . . . . . . . . . .. 28. 3.5.4. Communication . . . . . . . . . . . . . . . . . . . . . . . . . .. 28. 3.5.5. Electrical cabinet . . . . . . . . . . . . . . . . . . . . . . . . .. 28. 4 Materials 4.1. 4.2. 4.3. 29. Selection of materials . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29. 4.1.1. PLC - NX1P2-9024DT1 . . . . . . . . . . . . . . . . . . . . .. 29. 4.1.2. HMI screen - NA5-7W001B . . . . . . . . . . . . . . . . . . .. 30. 4.1.3. Ethernet switch . . . . . . . . . . . . . . . . . . . . . . . . . .. 30. 4.1.4. Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30. Possible handheld transmitter and receiver . . . . . . . . . . . . . . .. 31. 4.2.1. Comparing technical features . . . . . . . . . . . . . . . . . .. 31. 4.2.2. Chosen handheld transmitter . . . . . . . . . . . . . . . . . .. 32. 4.2.3. Considered handheld transmitters . . . . . . . . . . . . . . . .. 33. Control cabinet and components . . . . . . . . . . . . . . . . . . . . .. 34. x.

(16) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. 4.3.1. Cabinet materials . . . . . . . . . . . . . . . . . . . . . . . . .. 34. 4.3.2. Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36. 5 Design. 37. 5.1. Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 37. 5.1.1. Placement of components in electrical cabinet . . . . . . . . .. 38. Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39. 5.2. 6 Implementation. 41. 6.1. System overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 41. 6.2. Human Machine Interface . . . . . . . . . . . . . . . . . . . . . . . .. 41. 6.3. PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43. 6.4. Receiver and handheld transmitter . . . . . . . . . . . . . . . . . . .. 44. 6.5. Implementations due to corona . . . . . . . . . . . . . . . . . . . . .. 46. 6.5.1. 46. Administratively . . . . . . . . . . . . . . . . . . . . . . . . .. 7 Testing and Reviews 7.1. 47. Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 47. 7.1.1. Human Machine Interface . . . . . . . . . . . . . . . . . . . .. 47. 7.2. Handheld transmitter and receiver . . . . . . . . . . . . . . . . . . . .. 52. 7.3. Electrical cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 52. 7.4. Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 52. 7.4.1. Communication between PLC and HMI . . . . . . . . . . . . .. 53. 7.4.2. SD-CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 53. Prototype . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 53. 7.5. 8 Results. 54. 8.1. How the safety system works . . . . . . . . . . . . . . . . . . . . . . .. 54. 8.2. Result due to corona implementations . . . . . . . . . . . . . . . . . .. 55. 8.3. Graphical user interface for HMI. . . . . . . . . . . . . . . . . . . . .. 55. Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55. 8.4. PLC logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 60. 8.5. Receiver and handheld transmitter . . . . . . . . . . . . . . . . . . .. 61. 8.6. Prototype . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 62. 8.3.1. 9 Discussion. 64. xi.

(17) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. 9.1. Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 64. 9.2. Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 65. 9.3. Further Improvements and residual work . . . . . . . . . . . . . . . .. 66. 9.4. Separations from the prototype to a functional product . . . . . . . .. 67. 9.5. Experiences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 67. 9.5.1. Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 67. 9.5.2. Distribution of labor . . . . . . . . . . . . . . . . . . . . . . .. 67. 9.5.3. Challenges . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 67. 9.6. Hypothetical profitability . . . . . . . . . . . . . . . . . . . . . . . . .. 68. 9.7. Usage and reflection . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68. 10 Conclusion. 69. Bibliography. 73. Appendices. 74. A Cooperation Agreement. 74. B Progress Schedule. 76. C PC-Schematics. 78. D Sysmac Studio. 89. E QuickGuide. 94. F User Manual- Bridge. 96. G User Manual - Freezer room. 123. H User Manual - Handheld transmitter. 133. I. 142. Component list sent to Optimar. J Final cost estimation. 147. K Covid-19 risk analysis. 150. 11 Meeting reports. 156. xii.

(18) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. 12 Pre-project. 158. xiii.

(19) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. List of Figures 1. Personal injuries statistics . . . . . . . . . . . . . . . . . . . . . . . .. 1. 2. Collaboration Partners . . . . . . . . . . . . . . . . . . . . . . . . . .. 3. 3. Fishing vessels [39] [38] [40] . . . . . . . . . . . . . . . . . . . . . . .. 6. 4. Geir III [45] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7. 5. Freezer room [Geir II] . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8. 6. PLC system [37] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10. 7. Programming languages [4] . . . . . . . . . . . . . . . . . . . . . . . .. 11. 8. HMI system [23] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12. 9. HMI evolution [15] [18] [33] [9] [44] [10] . . . . . . . . . . . . . . . . .. 13. 10. Android GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14. 11. IOS GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14. 12. Industrial Remote controls from Tele-Radio [35] . . . . . . . . . . . .. 15. 13. HMI-Handbook [1] . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17. 14. Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18. 15. Eye Pattern [3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19. 16. Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19. 17. Sketch [7] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22. 18. Cable size [31] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24. 19. NX1P2-9024DT1 [20] . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29. 20. NA5-7W001B [19] . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30. 22. Rf-solution [26] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33. 23. FSL Electronics [25] . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33. 24. Control Cabinet [28] . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34. 25. Cabinet materials [12] [6] [30] . . . . . . . . . . . . . . . . . . . . . .. 34. 26. Cabinet schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 37. 28. Overview flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 39. 29. Overview information flow . . . . . . . . . . . . . . . . . . . . . . . .. 40. 30. System overview [17] . . . . . . . . . . . . . . . . . . . . . . . . . . .. 41. 31. HMI outside freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42. 32. HMI on bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43. 33. PLC tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44. 34. handheld transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44. 35. Receiver description . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45. xiv.

(20) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. 36. Transmitter description . . . . . . . . . . . . . . . . . . . . . . . . . .. 45. 37. Administrative implementations . . . . . . . . . . . . . . . . . . . . .. 46. 38. HMI Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . .. 47. 39. HMI test design 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 48. 40. HMI test design 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 49. 41. HMI test design 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50. 42. Homepage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 56. 43. Operation Panel For Bridge . . . . . . . . . . . . . . . . . . . . . . .. 57. 44. Admin Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 58. 45. Operation Panel For Freezer-Room . . . . . . . . . . . . . . . . . . .. 59. 48. Underside of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . .. 63. 49. Merge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 64. xv.

(21) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. List of Tables 1. Mandatory self declaration . . . . . . . . . . . . . . . . . . . . . . . .. i. 2. Publishing agreement . . . . . . . . . . . . . . . . . . . . . . . . . . .. ii. 3. Statistics for injuries happening in freeze room on fishing vessels, from Norwegian Maritime Authority [Personal injuries - 1981-2019] . . . .. 9. 4. Project functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23. 5. GUI functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23. 6. Cable color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24. 7. Logic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25. 8. Wireless transmitter and receive . . . . . . . . . . . . . . . . . . . . .. 25. 9. Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25. 10. Comparing technical features [26] [25] . . . . . . . . . . . . . . . . . .. 31. 11. Specific material list . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35. 12. Specific software list . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36. xvi.

(22) Bachelor, Spring 2020 Bachelor Thesis Automation. 1 1.1. Report. Introduction Background. 30th September 2010 the fishing vessel Geir II, located just outside of Tromsoe (Tromsø), experienced a fatal accident to one of it’s workers. The casualty was the factory manager on board. [Geir II] The ship was recently delivered from the shipyard, with DNV classification and initial inspection by the Norwegian Maritime Directorate. Much of the technology on board was already known and in use on the sister ship, but the area where the accident occurred was a pilot plant delivered by Optimar. This is one of the more severe personal injuries that have happened on a Norwegian fishing vessel, but it’s not the only personal injury that has occurred. Optimar is in the process of delivering equipment to the new vessel, Geir III. Geir III will be an improved version of the previous vessel, Geir II. One of the goals of this new vessel is to improve the safety of the workers.. Figure 1: Personal injuries statistics. 1.

(23) Bachelor, Spring 2020 Bachelor Thesis Automation. 1.2. Report. Project introduction. Optimar in Aalesund seeks to prove that an industrial safety system can minimize the outcome of accidents happening at fishing vessels. The most used safety system in freezer rooms today is camera surveillance. These camera surveillance systems are normally not manned, because of the economic aspects and time consumption. A solution to this problem can be an accommodating safety system that meets the needs of safety and with minimal effect to the work flow. Nowadays personnel working in freezers has no ideal way of contacting other workers or bridge personnel if an accident occurs. The large freezer compartments are normally located at the bottom deck and the accessibility to radio or other workers are often low to non existing. When an injury occurs time is of the essence. If a worker is crucially injured there should be a way of contacting bridge personnel and/or medical help. On the other hand if the worker is unconscious the system should automatically report an incident to bridge personnel. In this paper, the focus is on simplicity in design, user-friendly / accommodating, and finally saving lives or minimizing injuries. During consideration of different choices, the priority will be in low cost and accommodating it’s use.. 1.3. Bachelor degree specification. The final semester of the bachelor degree, for automation students at NTNU Aalesund, conducts a major project often given by companies. The purpose of this project is to give the students an introduction to project management. In addition to creating an association to the theory that has been applied over the years, and to convert the knowledge of theories to practice. The work of this project is set from mid January to mid May, and it’s calculated that each member of the group gets 500 work hours. After the project are completed and handed in to the supervisor the final grade will be conducted.. 2.

(24) Bachelor, Spring 2020 Bachelor Thesis Automation. 1.4. Report. Collaboration. Fish handling with care is the heart and everything for Optimar. Caring for both quality fish-handling and their customers needs has been a key factor in Optimar’s 80years long history. This philosophy has led Optimar to become a strong, competent and preferred supplier. Optimar AS is one of the world’s leading innovation companies in their field. The company offers technology in robotizing and automation and provides fish handling solutions and processing equipment adapted for vessels, land-based factories, and the fish farming industry.[21]. Figure 2: Collaboration Partners. 1.5. Limitations. In the spring of 2020 a pandemic emerged, Covid-19, influencing the thesis. This giving the thesis several limitations that will be further explained in the next chapters. The significant limitation of the thesis comes from the thesis itself. The bachelor project is a safety system, and safety systems should not be too complex. The importance of a safety system is it’s reliability, and therefore the need for complex features that could eventually fail is not needed.. 3.

(25) Bachelor, Spring 2020 Bachelor Thesis Automation. 1.6. Report. Aim and objectives. The purpose of the project is to design and develop a safety system that is industrial, and lifesaving. The group aims to design and develop a well-functioning safety system that is thoroughly documented and invites workers to turn around their routines. The system will be developed with the intention to be implemented in Geir III, to minimize the outcome of injuries. The main task will be to develop a system that is user friendly and meets the requirements set by Optimar AS. The group members will also gain knowledge and project experience that is relevant to future work relations. Core objectives for creating this system is mentioned below: • Design and develop a system that is suitable to operate in fishing vessels. • Design a suitable GUI that is user friendly and invites workers to turn around their routines and use the new safety system. • Suitable for the bridge personnel, maximum information in minimal view. • Program the logic so that the workers aren’t able to work around the system. • Make a system that is scalable and versatile. • Make the safety system redundant. • Develop a system that can be implemented in Geir III.. 1.7. Long term goals. • Minimize outcome of accidents • Saving lives • Develop a field leading safety system for freezer rooms in new vessels • Develop a system that can be retrofitted in existing fishing vessels. 4.

(26) Bachelor, Spring 2020 Bachelor Thesis Automation. 1.8. Report. Report Structure. This project report will describe the work and justify the choices made during the project period. Each chapter will have a brief introduction describing the content. The group starts by explaining the theory behind the techniques, technologies and materials used in the project, then how the group approaches the task. Furthermore, the group explains the results of the project and at the end the group will end up with a conclusion. The structure of the report is set up in an intuitive and simple way as shown below. Chapter 2 - Theory Elaborates the theory behind the essentials used during the project. Programming languages, communication methods, systems, special equipment used and programs. Chapter 3 - Approach This is a brief description of what is considered as the required specifications, as well as how to approach tasks and problems to develop the system. Method of planning, approach and adjustments are explained. Chapter 4 - Materials Contains all the materials, components and information that is used to create the safety system. Chapter 5 - Design Explains the design of both hardware and software. Chapter 6 - Implementation Elaborates how the system is implemented, how components were installed. Chapter 7 - Reviews Explains the testing of the system and how the prototype has been changed throughout the project, and how the problems that occurred were solved. Chapter 8 - Results Presents the results, and how the systems performs. Chapter 9 - Discussion Discusses the final result, students learning profit from the assignment. Also, some suggestions for further improvement of the prototype is mentioned. Chapter 10 - Conclusion Summarizes the level of completion of the project and concludes the bachelor report.. 5.

(27) Bachelor, Spring 2020 Bachelor Thesis Automation. 2. Report. Theoretical Basis and Background. In this chapter, the theory behind components and principles used are presented. Theory as presented underneath will be necessary for making decisions throughout the project.. 2.1. Fishing vessels and fish handling. There are many different fishing vessels on the ocean today. Trawls, seiners and line vessels are some of them. A trawler is a fishing vessel that is designed to use trawl nets in order to catch a large volume of fish. Seiners uses surroundings and seine nets and line vessels uses one or more long heavy fishing lines. [43]. v Figure 3: Fishing vessels [39] [38] [40] All of these fishing vessels mentioned above have a freezer compartment where the fishes are stored. Once the fish has been cleaned and treated on the factory deck it has to be frozen in blocks of about 25-50kg before it is brought down to the freezer compartment.[43]. 6.

(28) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.2. Report. Geir III. Geir III is a fishing vessel manufactured by Skipsteknisk AS and is defined as a longliner. At a length of 61.80 meters and a width of 13.50 meters, Geir III ordered by HP Holmeset, will be one of the biggest and most modern vessels of it’s kind in the world. The vessel will be equipped with moonpool[M] and autoline equipment for approximately 70,000 hooks. Geir III will be able to produce both frozen HG[HG] and fillets, and has a loading capacity of 500 tonnes. The shipping company is now further developing the concept from its previous vessel Geir II, and improvements are being made such as moonpool, block hotel, factory and propulsion solution. [16]. Figure 4: Geir III [45]. 7.

(29) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.3. Report. Freezer room. In this modern days as technology evolves the refrigeration system temperature is between -30°C to -35°C. The walls and doors are four to six inches thick and are often made of galvanized steel, stainless steel or aluminum. The freezer compartments of the various fishing vessels are u filled with 500 tonnes of fish and transport equipment such as a truck, so that it’s possible to move around on pallets and stack. The size of the freezer compartment in the fishing vessels depends on the type of vessel, but it usually has a ceiling height of 4-6 meters. Camera surveillance is used in several of these freezer rooms, but there are also some fishing vessels that doesn’t have this type of surveillance. Although some freezer rooms may be cctv monitored, these cameras aren’t manned for surveillance, and may contain blind spots. [8] 2.3.1. Working inside a freezer. When you’re inside a tightly sealed, extremely cold giant metal box you need to worry about hypothermia, frostbite and air supply. The normal core body temperature of a healthy person is between 36,5°C and 37,5°C . Hypothermia occurs when a person’s core temperature drops significantly below normal. A person suffering from hypothermia will become tired and confused. There have been several instances where workers inside the freezer have been trapped, between pallets and lifts, which have caused workers to experience hypothermia and then perish. A list of injuries that occurred in freezer rooms from 2010 to 2020 is shown bellow. [27]. Figure 5: Freezer room [Geir II]. 8.

(30) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Injury statistics at freezer room on fishing vessels Date of injury 27.02.2010 14.06.2010 06.07.2010 02.01.2011 23.04.2011 26.04.2011 12.10.2011 06.10.2012 10.11.2012 09.01.2013 04.05.2013. ————————– Injury group Shock / crush injury Shock / crush injury Shock / crush injury Shock / crush injury Tripping injury injury Shock / crush injury Tripping injury Tripping injury Shock / crush injury Tripping injury Shock / crush injury. 02.01.2015 30.03.2016 08.05.2016 12.05.2016. Tripping injury Chemical injury Shock / crush injury Shock / crush injury. 12.05.2016 29.08.2016 31.10.2016 13.09.2017 07.10.2017 19.10.2017. Shock / crush injury Shock / crush injury Shock / crush injury Tripping injury Shock / crush injury Shock / crush injury. 03.11.2017. Shock / crush injury. 10.11.2017 11.11.2017 17.12.2017. Shock / crush injury Stick / cutting injury Poisoning. 15.02.2018 12.03.2018 15.08.2018 13.11.2018 12.06.2019 28.06.2019 19.08.2019 18.12.2019. Tripping injury Shock / crush injury Poisoning Shock / crush injury Load Injury Tripping injury Tripping injury Chemical injury. Work related to injury Distribution of fish on board Distribution of fish on board Harvesting treatment Distribution of fish on board Distribution of fish on board Loading / unloading Unknown Distribution of fish on board Distribution of fish on board Distribution of fish on board Other work / monitoring of loading / unloading operations Unknown Unknown Unknown Packaging and storage of frozen fish in cargo Unknown Unknown Unknown Unknown Distribution of fish on board Packaging and storage of frozen fish in cargo Other work / monitoring of loading / unloading operations Distribution of fish on board Unknown Packaging and storage of frozen fish in cargo Distribution of fish on board Harvesting treatment Unknown Unknown Unknown Unknown Unknown Unknown. Table 3: Statistics for injuries happening in freeze room on fishing vessels, from Norwegian Maritime Authority [Personal injuries - 1981-2019] 9.

(31) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.4 2.4.1. Report. Industrial Equipment Programmable Logical Controller. PLC stands for Programmable Logical Controller and it is an industrial computer which is adapted for the control of manufacturing processes. PLC was introduced by Richard Morley in late 1960s. Initially the PLC was a replacement for panels of relays. The use of relays was time consuming, challenging and not very space efficient. A PLC does need some equipment. To install a PLC you need a CPU module and input/output devices called I/O. The CPU communicates with the I/O. The PLC also require a power supply.[22]. Figure 6: PLC system [37]. 10.

(32) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.4.1.1. Report. Programming Language, IEC 61131-3 standard. IEC 61131-3 standard is the international standard for programming languages used in PLCs. PLCs from different manufacturers can be programmed in many different ways, and the most used languages is listed below. • Ladder Diagrams (LD) are specialized schematics. They are called “ladder” diagrams because they resemble a ladder, with two vertical rails (supply power) and as many “rungs” (horizontal lines) as there are control circuits to represent. • Structured Text (ST) is a high level language that is block structured and syntactically resembles pascal on which it is based. • Function Block Diagram (FBD) is a graphical language, that can describe the function between input variables and output variables. A function is described as a set of elementary blocks. [24]. Figure 7: Programming languages [4]. 11.

(33) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.4.2. Report. Human-Machine Interface. HMI is used in the industry to control and monitor machines. A very common HMI that almost every person has used, is an ATM machine. The screen and push buttons allows you to operate the machine to dispense a certain amount of money or deposit money. Industrial HMI will many times be in a form of a screen, often touch screens. An operator or maintenance personnel can operate and monitor the machine from the HMI. The HMI may include information such as temperature, pressure, process stats and material counts. An HMI screen can be connected to a PLC, and monitor several systems at the same time, as shown in the picture below. [23]. Figure 8: HMI system [23] The picture and information above, is gathered from an educational video from GalcoTV. If more information is desirable about HMI’s follow the link and watch the video [What is an (HMI) Human Machine Interface? - A Galco TV Tech Tip]. 12.

(34) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.4.2.1. Report. The evolution of the HMI. The evolution of the HMI has changed dramatically the last years, and has gone from push buttons to touch screens, from text-based to graphical and from manual to automated control. This evolution has brought along concepts like "Visualization", Graphical user interface, user friendly and much more. [14]. Figure 9: HMI evolution [15] [18] [33] [9] [44] [10]. 13.

(35) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.5. Report. Graphical user interface (GUI). A GUI (Graphical User Interface) is a type of graphical visualisation interface which makes it possible for humans to interact with systems, machines and other devices. These types of interactions is represented in form of pictures, buttons, input fields and other graphical elements. With GUI’s an user interacts directly with the device and not by programming or via textual commands. Almost everyone interacts with GUI’s in there daily life. Either you use your smartphone, computer or withdrawal at ATM’s. [29] Some commonly known GUI’s most people use: Ô Android. Figure 10: Android GUI Ô Apple iOS. Figure 11: IOS GUI 14.

(36) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.5.1. Report. Industrial Remote controls. Industrial remote controls comes in many different wrappings and usages. In this thesis the main aspects of industrial remote controllers will be based in wireless handheld controllers. A wireless remote control is a safe and convenient way of controlling a piece of machinery or system. Most wireless remote controls is programmable and therefore programmed to desired usage. One of the most obvious benefits of a wireless controller is that you don’t need to move back and forth to the machine or control panel to operate the machine or system. By doing this, the operator becomes mobile and can operate the machine or system at desired position or by doing other work. A wireless controller will also not be in the operators way, like cable bound systems. By doing so one can avoid all maintenance needed due to damage or corrosion and reduces the safety hazard, such as tripping hazard.[36]. Figure 12: Industrial Remote controls from Tele-Radio [35]. 2.6 2.6.1. Communication protocols Ethernet- protocol. Ethernet is the most common technology used in local are networks and is specified in the IEEE 802.3 standard. Ethernet was originally developed by Xerox and further by Xerox, DEC and Intel. Networks using Ethernet network technology can consist of either coaxial cables, twisted pair cables, fiber optic cables, or wireless called WLAN. The technology typically allows data transfer at speeds of 10 Mbps [42]. 2.6.2. Ethernet/IP. Ethernet/IP is an industrial network protocol that adapts common industrial protocols to standard Ethernet. It was introduced in early 2000 to most industrial Ethernet solutions. Part of the reason is based on open technology. [41]. 15.

(37) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.7. Report. Maritime electrical installation. Norwegian directorate for civil protection [dsb] has a given set of standard that are relevant to this bachelor. See link to Regulations relating to maritime electrical installation. Chapter V – Supplement about safety of fishing vessels of 15 meters in length and over – Precautions against shock, fire and other hazards of electrical origin. [5]. 2.8. Wiring. When working with electrical systems it’s important to choose the correct cabling type and size. Choosing the right type of cable is important, because of the impact the cable has to withstand from the environment and the safety regarding fire other electrical related accidents. The cable size is vital in an electrical system because of safety. The cable needs to be big enough to withstand the heat generated by the current flowing through the cable. Wiring for AC and/or DC electrical circuits, colour codes are crucial for identifying the individual wires. IEC, AC: Most of Europe abides by IEC (International Electrotechnical Commission) wiring color codes for AC branch circuits. [2]. 16.

(38) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.9. Report. HMI Guidelines. ISA 101 seems to be the most active development in recent HMI standards, world wide. ISA is known as The International Society of Automation, formerly known as The Instrumentation, Systems, and Automation Society.. Figure 13: HMI-Handbook [1] Modern human machine interfaces(HMI) provide means to the operators to see, touch and control high stress industrial processes through touch screen displays. Two major factors on HMI screens; 1. The screen must be able to hold operators attention with maximum display clarity 2. The design must allow a person with no training or little experience to be able to successfully operate a machine. 2.9.1. Background Color. Warm colors such as red, yellow and orange are colors that will draw one´s attention to particular areas of the HMI display. Use of such warm colors is not relevant for large areas of the screen. Cool colors make better backgrounds and theme colors, because of their tendency towards balanced representation of feelings. HMI graphic should have a dull background, grey is the preferable one. Animation and crossing lines should be avoided so that the operator does not get distracted from important data. Primary colors such as red, green, blue should never be used as background, cause of their ability to cause a glare.. 17.

(39) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.9.2. Report. Color Choice For Objects. According to the HMI handbook and HMI design Standard there are few colors that should specifically be used for certain operations. The use of colors for the indicators should be:. Figure 14: Colors 2.9.3. Text. Texts on the HMI screen is the simplest way to relay information to the user, but the screen should contain minimum amount of text. Choices of text should be in a readable format, for optimal user experience. 2.9.4. Alarm. Alarm information is the most important part in the HMI screen design. An operator should not be uncertain when an alarm is active. Colors such as red and yellow attract one’s attention. It is necessary that such colors are used for alarms.. 18.

(40) Bachelor, Spring 2020 Bachelor Thesis Automation. 2.9.5. Report. Layout. A screen layout is important for a good HMI display. A human normally scans an HMI screen as any other regular screen, starting from the top left corner to right and then down the screen. The important objects of a system should be placed in an area within the page where the users attention easily goes. The alarms should pop up in the middle of the screen, and key data on the center right of the page.[11]. Figure 15: Eye Pattern [3]. Figure 16: Design. 19.

(41) Bachelor, Spring 2020 Bachelor Thesis Automation. 3. Report. Approach. Chapter three provides an understanding of what has been important to the project regarding the desired quality, requirements and specifications. This includes group organization and how we have chosen to solve the task.. 3.1. Approach due to the Covid-19. In the spring of 2020 a pandemic emerged, Covid-19, influencing the thesis. Due to the lack of a risk analysis to a pandemic, this had to be conducted during the thesis. The analysis of Covid-19 became a constant analysis with regard to the shifting news picture. All members had to stay updated to the shifting news pictures, measurements taken by NTNU and the Norwegian government. The total risk analysis can be read at attachment [K] and the implementations due to Covid-19 is elaborated in section [6.5] implementation.. 3.2. Project organization. The group has selected a group leader and a group secretary. The group leader in this case is responsible for ensuring that all assigned tasks are completed, and has an overview of what has not been done and what needs to be done. He will be our main contact person throughout the project. To manage disagreements and working hours throughout the project, a Cooperation Agreement was made.[A] The group secretary is responsible for the main report. The secretary is also responsible for organising meetings and will be taking the lead of running the team when the leader is unable to attend the meeting Apart from this, all members are responsible for ensuring that all tasks assigned to them are completed. In an early phase of the project, a project plan was made in Instagantt, to ensure pathway and end stop for the project. This plan is detailed and includes all tasks each team member is assigned to. To see the full Instagantt plan see attachment [C]. The project report will be processed throughout the project. Once a week, as long as there are new information, there will be held a meeting with the supervisor. During the weekly meetings the topics will be around status of the project, problems we have encountered and new solutions. To get a more elaborated approach view pre-project [12].. 20.

(42) Bachelor, Spring 2020 Bachelor Thesis Automation. 3.3. Report. Project description. Optimar is in the process of delivering equipment to the new vessel, Geir III. Geir III will be an improved version of the previous vessel, Geir II. One of the goals of this new vessel is to improve the safety of the workers. Large freezer compartments are normally located at the bottom deck and the accessibility to radio or other workers are often low to non existing. When an injury occurs, time is of the essence. If a worker is crucially injured there should be a way of contacting bridge personnel and/or medical help. On the other hand if the worker is unconscious the system should automatically report an incident to bridge personnel. The task will be to develop an accommodating safety system that encourages the workers to change their habits, and take in use new routines. The approach of the task is sectioned in main parts. Testing, modifying and assembly will happen simultaneously à Specifying main description à Brainstorming functions à Hardware à Software à Prototype à Reviews and testing. 21.

(43) Bachelor, Spring 2020 Bachelor Thesis Automation. 3.3.1. Report. Specifying main description. The ideal solution is a safety system where workers is obligated to use a handheld transmitter that is brought into the freezer when entering. The handheld transmitter is used by the worker to call for help if needed. The worker also has to press a button on the device every given amount of time, if the button is not pressed, an alarm will be triggered. To control the system, two HMI screens shall be used, one at the entrance of the freezer room and one at the bridge. Outside the freezer entrance there shall be a charging station for the handheld transmitter. Finally, a user-friendly interface should be designed where history can be viewed. This user interface should give an overview of who works in the freezer at any given time. If the worker is inside the freezer and calls for help with the handheld transmitter, an alarm will go off on the user interface. This alarm will also be triggered if the worker inside the freezer fails to press the button within the given time frame.. Figure 17: Sketch [7]. 22.

(44) Bachelor, Spring 2020 Bachelor Thesis Automation. 3.3.2. Report. Brainstorming functions. Must have 24V separate powered system Portable, wireless and rechargeable transmitter Alarm if workers fail to report Alarm if workers reports a injury Two HMI screens, bridge and freezer Password protected admin page. Should have Inviting and user friendly gui Transmitter for one hand use Alarm with light and sound Alarm with light and sound Quick view GUI for bridge Possibility to change timers and add workers. Could have Logging of alarms Vibrate or light to signal worker to report Phone message for sleeping health personnel Phone massage for sleeping health personnel UPS/battery if power disappears Add possible phone messages. Table 4: Project functions Function Admin min mode/page. Description Password protected mode. Alarm log. System for logging all alarms back in time "Second worker logging in" A menu when "logging" in to freezer to select given worker. Worker nr.2 Overview of workers displayed. Table 5: GUI functions. 23. Reason Adjustment of div. variables and add users Event overview Simple and user friendly Overview of who was/is inside freezer.

(45) Bachelor, Spring 2020 Bachelor Thesis Automation. 3.3.3. Report. Hardware. There is a lot of equipment that is necessary to carry out a project of this scale. This sub chapter takes care of the main components needed to build a system explained and brainstormed in the two sub chapters above. Chapter 4 will contain a more specific material list with manufacturer and explanation of why the given component was chosen. 3.3.3.1. Cable size and color. Small electronics works with a power supply at 12v or 24v. These voltages are so low that a cross section at 0.75 is ideal. Other measurements that plays a role in choosing the thickness of the cable is how many cables that are going to lay next to each other. More cables next to each other will conduct more heat, but with only 12v or 24v this will not be an issue.. Figure 18: Cable size [31] Rounding up to cable sizes is 0.75mm2, 1.5mm2, 2.5mm2, etc.. [32] When it comes to color the group will follow the standards from Optimar Earthing 230V + 230V 24V + 24V Signal. Green and yellow Blue Brown Red White Orange. Table 6: Cable color. 24.

(46) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Logic components. Component PLC HMI screen Ethernet switch Power supply Relay. ————————– Usage Programmable logic controller, used for the logic of the system To display events and to control freezer For communication between PLC and HMI screens To power the system Trigger input on receiver. Amount 1 2 1 2 2. Table 7: Logic components. Wireless transmitter and receiver Component Wireless handheld transmitter Wireless receiver Charger Antenna. ————————– Usage Used inside freezer by worker to acknowledge To communicate with the handheld transmitter and PLC User-friendly, no need to change battery Antenna to receive signal from handheld transmitter. Can withstand the low temperature better than receiver. Amount 1 1 1 1. Table 8: Wireless transmitter and receive. Control cabinet. ————————– Usage The interface between what is placed inside the cabinet Terminal blocks 24V Order, overview and safety Terminal blocks earth Common ground point Terminal blocks end plate Electrical Safety Terminal blocks numbering Order, overview and safety Cable gates (slotted channel) Order, overview and safety Mounting rail Mount equipment to cabinet Component Terminal blocks 230V. Table 9: Control cabinet. 25. Amount x x x x x x x.

(47) Bachelor, Spring 2020 Bachelor Thesis Automation. 3.3.4. Report. Software. There are different types of software that will be used in the thesis for different tasks, more about the given software in section [4.3.2]. This sub chapter will focus on the approach of each software. 3.3.4.1. Electrical drawings. The electrical schematics will be constructed by gathering as much information about the different materials and their way of wiring. An electrical sketch will be made and again controlled when all materials arrives. Then a final drawing will be made, controlled by all group members before finalizing. 3.3.4.2. Graphical User Interface. Three versions of the GUI will be made, one by each group member. The GUI’s will then be combined into one, giving the GUI the benefit of multiple choices in design patterns. By doing so all members would get familiar with Sysmac studio, and knowledge of designing a GUI will be gained. Table [5] and [4] gives a function overview that all members will have to take into consideration when designing the GUI. All members creativity should float but within some restrictions. See chapter [7.1.1] for the different designs of the GUI and chapter [8.3] for the end result. 3.3.4.3. PLC Program. The PLC program will be conducted by creating a flow chart describing the flow of information and behavior, and then the code will be constructed based on these flowcharts. The code will be programmed based on the PLC language, structured text. The license gathered for the PLC program does not support version control or a collaboration systems, like git. The work around will be to program the PLC based on functions, function blocks and programs working in parallel, making it easy for collaborating and combining programs.. 26.

(48) Bachelor, Spring 2020 Bachelor Thesis Automation. 3.3.5. Report. Prototype. During the pre-project phase of the thesis it was decided to design, build and manufacture a prototype of the system. The prototype will be a display of the completed product. The main goal of the prototype is to design and create a compact control cabinet, that requires minimal effort for installation. • Connect the 230 V to the given terminal blocks • Route an Ethernet cable and mount the HMI screen at the bridge with a power supply. • Mount the antenna in the freezer. 3.4. Reviews. An important part of the thesis is the review and test phase. During the review and test phase the focus will be on discovering faults, shortcomings and qualities. This to ensure the quality of the final product. å Hardware Review of hardware is necessary to ensure that the entire system with all the different parts works together properly. å Software A Software review is needed to avoid errors in the code. A systematic examination of the code, and an inspection to find defects. å Design To avoid collision in the electrical cabinet. If there is a case where the system needs maintenance or service, it is necessary that equipment can easily be replaced without any major cabinet changes. The design of the GUI should be user friendly and reliable. Therefore, our design review will consist of; ¬ Physical tests Engineering simulations ® Examinations. 27.

(49) Bachelor, Spring 2020 Bachelor Thesis Automation. 3.5. Report. Testing. Throughout the project, several tests has to be done. All tools and equipment will be tested before being used. 3.5.1. HMI. Based on the different GUI designs, we must test which one works optimally for the user. With regard to the visibility of different buttons, screen brightness and whether it is user friendly. 3.5.2. PLC. Based on given functions and logic of the system, it’s important to constantly test new functions. It will then be easier to troubleshoot if something goes wrong. It’s also important to test that the logic is working as desired with the different equipments. 3.5.3. Handheld transmitter and receiver. The handheld transmitter must be tested in several robust tests. It will be tested to see if buttons, buzzer and LED’s works optimally in low temperature environments. The device should sit properly on a worker while moving and doing heavy work, without being an annoyance. 3.5.4. Communication. Before everything is assembled in the electrical cabinet, the communication between each component unit would have to be tested. For our system to work, each unit must communicate with each other in some way. Below is a step-by-step overview of what tests that will be done; • Communication between Sysmac Studio and PLC • Communication between Sysmac Studio and HMI • Communication between HMI and PLC • Communication between Receiver and PLC • Communication between Receiver and handheld transmitter 3.5.5. Electrical cabinet. It is important to measure to see if all of the equipment gets the power it requires, so that the components do not get damaged. Each group member should go through the connection of the cabinet and check the voltage values with a voltmeter to test the connections and the power supplied to the components.. 28.

(50) Bachelor, Spring 2020 Bachelor Thesis Automation. 4. Report. Materials. This chapter deals with the choice of materials, why these materials were chosen, and how they met the expectations and requirements of the group and Optimar.. 4.1. Selection of materials. During the pre-project[12] research regarding different manufactures and parts needed for this project was conducted. A list of parts needed can be read at [7] [??] [??]. Furthermore the group had meetings with Optimar discussing subjects as specifying the thesis, parts needed and manufacturers they were using. After a lot of research and discussion, a list of components with optional handheld transmitters was sent to Optimar, refers to list at attachment [I]. Optimar has a partnership with Omron Electronics and wanted the group to choose most of the parts needed from them. Regarding to one of the main component (handheld transmitter) a proper research was required. We were told that the company Tele-Radio AS had possible units that could work in our system. In terms of budgeting, no specific requirements were given. 4.1.1. PLC - NX1P2-9024DT1. To control the logistics of this type of system a PLC is required. The NX1P2-9024DT1 was recommended to the group by Optimar. This PLC is relatively cheap and has all specifications needed. The PLC has Ethernet/IP, SD card support and I/O that meets the groups requirements. The PLC is a NX model which means it can be programmed by the Sysmac Studio IDE.. Figure 19: NX1P2-9024DT1 [20]. 29.

(51) Bachelor, Spring 2020 Bachelor Thesis Automation. 4.1.2. Report. HMI screen - NA5-7W001B. In the bachelor thesis description, it states that two HMI screens is needed. The HMI screens that Optimar recommended to the group was the NA5-7W001B. This is the smallest and the cheapest screen in the NA class of HMI screens. The GUI will have a limited amount of information to display, and because of this the group and Optimar concluded that the 7 inch screen will be big enough for this project. The screen is an NA model, which means it also can be programmed by the Sysmac Studio IDE, and is directly compatible with the chosen PLC.. Figure 20: NA5-7W001B [19] 4.1.3. Ethernet switch. The PLC that was chosen is only equipped with one Ethernet/IP port. This led to the need of an Ethernet switch to serve the two HMI screens needed. The FL SFNB 5TX ethernet switch from Phoenix Contact with 5 ports was chosen due to the possible need of scalability in the future. 4.1.4. Power supply. To supply the system with power, a power supply must be chosen. The power supply needs to power a HMI screen,PLC, Ethernet switch and a receiver module. After a discussion with Omron, they recommended a 120w power supply. The S8VK-G12024 power supply satisfies this specification, and chosen for this project. An additional power supply of the same model will also be used to supply the HMI screen, located on the bridge, with power.. 30.

(52) Bachelor, Spring 2020 Bachelor Thesis Automation. 4.2. Report. Possible handheld transmitter and receiver. When choosing handheld transmitter and receiver a set of criteria were set by Optimar. The importance of the transmitter was it’s capability to work in the temperature of a freezer room, be rechargeable, durable, easy to use and with the possibility to notify workers to acknowledge. The receiver needed to correspond with a given transmitter. Research around handheld transmitter was concluded, and a list of handheld transmitters and their specifications was sent to Optimar for consideration. A list with specifications of the handheld transmitters that was considered for use and the chosen device can be read underneath. 4.2.1. Comparing technical features. Product. Handheld Cooperation Range Operating temp IP rating Rechargeable Remote antenna Led indicator Vibration Buzzer Fulfilling criteria. Rf-solution. FSL Electronics. Tele-radio. X ×. X ×. up to 2000m -10 * 50C IP68. up to 300m 10 * 50C IP55. X X. Long range -20 * 55C IP66. × X ×. X X X. X X X × X X. Unknown Unknown. Unknown Unknown. ×. ×. Table 10: Comparing technical features [26] [25]. 31.

(53) Bachelor, Spring 2020 Bachelor Thesis Automation. 4.2.2. Report. Chosen handheld transmitter. 4.2.2.1. Tele-radio - Tiger G2. Tele-radio and their Tiger G2 series became the chosen handheld transmitter with corresponding receiver. Several aspects were weighted when choosing handheld transmitter, [4.2.1]. The main reason for choosing Tele-radio and their Tiger G2 series was the temperature certification. Tiger G2 has 8 programmable buttons, LED lights and buzzer functionality. The receiver has plenty of inputs and outputs for communication. Tele-radio do also deliver custom solutions were receiver can be pre-programmed and transmitter tailored to the needs of the customer. Optimar has cooperated with Tele-radio in their previous projects, giving them discounts and tailored solutions. All of the aspects above together with the functionality of the transmitter and receiver resulted in the selection of Tele-radio and the Tiger G2 series.. (a) Tiger G2. (b) Tiger receiver [34]. 32.

(54) Bachelor, Spring 2020 Bachelor Thesis Automation. 4.2.3. Report. Considered handheld transmitters. 4.2.3.1. RF Solutions. The handheld transmitter from RF Solution didn’t reach the technical standards, and therefore was not the chosen handheld transmitter. Optimar did not have a cooperation with Rf-solution and no previous experience with the product. At the same time the device was not rechargeable and had a low operating temperature tolerance.. 4.2.3.2. FSL Electronics. The handheld transmitter from FSL Electronics were considered because of it’s design. Optimar liked the watch design and simple button layout. The problem with FSL Electronics was mainly the operating temperature. The device wasn’t made to operate in sub-zero temperatures.. Figure 22: Rf-solution [26]. Figure 23: FSL Electronics [25]. 33.

(55) Bachelor, Spring 2020 Bachelor Thesis Automation. 4.3. Report. Control cabinet and components. The most important specification when choosing the control cabinet is the size and that the cabinet is made out of a stainless steel. To ensure that the cabinet is big enough we chose a cabinet with a height of 600mm, a width of 380mm and a depth of 215mm. If the group struggles to find a control cabinet at an affordable price, Optimar offered to give away one of their cabinets to us.. Figure 24: Control Cabinet [28] 4.3.1. Cabinet materials. The given materials are needed to mount or keep the control cabinet organized. All materials are given from Optimar and their cabinet making department. The given pictures are just a visual view of the products. From left to right: Terminal blocks, slotted channels and mounting rails.. Figure 25: Cabinet materials [12] [6] [30]. 34.

(56) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Hardware material. Manufacturer Omron Omron Phoenix Contact Phoenix Contact Phoenix Contact Omron Tele-radio Tele-radio Tele-radio Phoenix Contact Rittal Phoenix Contact Obo bettermann EFA Unknown HelaDuct Unknown Unknown Unknown Unknown Unknown Unknown. ————————– Component Model Controller/PLC NX1P2-9024DT1 HMI screen NA5-7W001B Ethernet switch FL SWITCH SFNB 5TX Relay socket PLC-BSC24DC/21 Single relay REL-MR24DC/21 Power supply S8VK-G12024 Handheld sender Tiger G2 Antenna 1/4-433K1 Receiver Tiger receiver Terminal Blocks Earthing Cabinet Stainless steal Terminal Blocks Normal Slotted channel Gray PVC 50x60 with lid Mounting rails TS 35 Hullet PTFE spiral hose Serie SBPTFE Flexible cable pro- HelaDuct Flex tection Yellow/green cable 1,5 mm2 Brown cable 1,5 mm2 Blue cable 1,5 mm2 Black cable 0,75 mm2 Red cable 0,75 mm2 Orange cable 0,75 mm2 Table 11: Specific material list. 35. Quantity/size 1 2 1 2 2 2 1 1 1 2 600x380x210 mm 6 ca 2m ca 0,5 m ca 0,2 m ca 0,3 m ca ca ca ca ca ca. 0,5 m 0,3 m 0,3 m 02 m 2m 1m.

(57) Bachelor, Spring 2020 Bachelor Thesis Automation. 4.3.2. Report. Software. There are different types of software used in the thesis for different tasks. Asana and Instagantt: Instagantt together with Asana was used in order to keep track of all the assignments for the bachelor thesis. Asana and Instagantt were the chosen software for keeping track of all the assignments because it was recommended by earlier students and supervisors. AutoCAD 2020 and AutoCAD Electrical 2020: AutoCAD 2020 is a widely used software to design almost everything. AutoCAD 2020 is the software tool Optimar uses to design and draw there electrical drawings. Optimar wanted the group to use Autocad 2020 and the electrical version for electrical drawings Autocad Electrical 2020. The group found it tricky using these software tools because there was few libraries for electrical components and a complex program to learn. After discussions with Optimar, the group and Optimar agreed to use Pcschematic. Pcschematic Automation 40: Pcschematic is a program that the group has earlier experience with, through work and school. Because of the previous experience the group and Optimar agreed to do all electrical drawings in Pcschematic. Sysmac Studio: Sysmac Studio is used to program all NX and NA devices from Omron. The chosen devices, PLC and HMI requires Sysmac Studio to be programmed, making Sysmac studio the chosen software for programming PLC and HMI. Overleaf : Overleaf is a free web-based text editor for latex. This text editor was chosen because of its simplicity, cloud based storage and it’s capability of real time editing with several users.. Software material. Manufacturer Asana Asana PCShematic Autodesk Autodesk Omron Overleaf. ————————– Software Instagantt Asana Automation 40 AutoCAD AutoCAD Electrical Sysmac studio Overleaf. Version 2019 2019 2020 2020 2020 1.3 2020. Table 12: Specific software list. 36.

(58) Bachelor, Spring 2020 Bachelor Thesis Automation. 5. Report. Design. This chapter will explain how the most essential parts have been used to create a finished product. The explanation underneath will take care of how both hardware and software was planned and designed for the finalized result.. 5.1. Hardware. The prototype is created as a finished product, hence minimal work is needed to install the safety system. The design requires 4 minimal operations for it to function: • Connect the cabinet to 230v • Mount antenna in freezer room • Route an ethernet cable to the bridge • Mount the HMI screen with a power supply at the bridge. Figure 26: Cabinet schematics. 37.

(59) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. (a) Front Cabinet. 5.1.1. (b) Inside Cabinet. Placement of components in electrical cabinet. The components was placed in a way that made sense to the group. All the terminal blocks were placed at the bottom, since this is where all the cables comes through the cabinet. The PLC, power supply and Ethernet switch was placed in the middle of the cabinet because it’s easily accessible to all the other components. The receiver was placed at the top, since it was the only unoccupied space left.. 38.

(60) Bachelor, Spring 2020 Bachelor Thesis Automation. 5.2. Report. Software. To visualize and explain the system, two flow chart diagrams was used. One flowchart to show the overview sequence and one flowchart that also explains how the information flows between the PLC, the HMI screens and the handheld transmitter. Overview flowchart. Figure 28: Overview flowchart. 39.

(61) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Overview information flow. Figure 29: Overview information flow. 40.

(62) Bachelor, Spring 2020 Bachelor Thesis Automation. 6. Report. Implementation. This chapter will explain how the approach, materials and design were implemented in the finalized product.. 6.1. System overview. Figure [30] shows an overview of the safety system. The system consists of 2x HMI screens, a PLC with connecting software (Sysmac Studio), a receiver and a handheld transmitter. The connecting lines shows the information flow.. Figure 30: System overview [17]. 6.2. Human Machine Interface. The human machine interface is a platform that makes it possible for the user to interface with the rest of the system. The graphical user interface consists of pages with buttons, lamps and other tools to edit or display global variables from the PLC. For this project, two HMI’s was used. The first interface is to be located outside the freezer-room. This HMI screen has two main tasks. 1. Check workers in and out of the freezer 2. Call for help if an accident occurs. 41.

(63) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Figure 31: HMI outside freezer The second interface is mainly used for administrative tasks, display warning and alarms to the workers on the bridge. In the administrative page one can manage users and timer variables. The lamps on the operation page displays if workers are inside the freezer, if a receipt is being requested by the PLC, if a warning occurs and if an alarm occurs. A pop-up window will be displayed if the worker inside the freezer is requesting assistance from another worker, or requesting medical support.. 42.

(64) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. Figure 32: HMI on bridge. 6.3. PLC. The PLC controls the logic of the system and is the main controlling unit. The PLC receives information from the two HMI screens and the receiver. This information is then processed and passed on to the given components or outputs that have been delegated. The PLC used in the project has five main tasks: 1. To keep track of timers. Describing when to request a receipt from the user and when to sound the alarm. 2. To sign workers in/out to the system when they check in/out. Making sure only two workers can be logged in at a time and that they can log both in and out without errors occurring. 3. To share information between the HMI screens, making sure that both HMI screens can communicate with each other. 4. To read and write variables to the SD card. This is done so that usernames and timer variables is not lost after a potential reboot or power outage of the system. 5. To receive and send data to the receiver. Data received from the receiver consists 43.

(65) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. of two boolean values that correlates to the two buttons on the transmitter. Data that is sent to the receiver is two boolean values, saying whether or not to activate the buzzer and LEDs on the transmitter.. Figure 33: PLC tasks. 6.4. Receiver and handheld transmitter. Both the receiver and the handheld transmitter is a pre-programmed system delivered by tele-radio. These two units together forms the link between the worker inside the freezer and the PLC logic.. Figure 34: handheld transmitter. 44.

(66) Bachelor, Spring 2020 Bachelor Thesis Automation. Report. The receiver and transmitter consists of several parts:. Figure 35: Receiver description The main purpose of the receiver is an antenna receiving signal from the handheld transmitter. The signal from the transmitter is then converted to a mechanical operation making a corresponding relay close or open. The open or closed signal is then passed on to the input terminal on the PLC. There is also a couple of digital inputs on the receiver. These inputs is used to activate the buzzer and the LEDs on the transmitter.. Figure 36: Transmitter description The handheld transmitter have eight buttons, but two that are functional when in use. Button 4 is to acknowledge, and button 3 is to sound the alarm at the bridge. To cancel a false alarm, both buttons can be held down for three seconds.. 45.

(67) Bachelor, Spring 2020 Bachelor Thesis Automation. 6.5. Report. Implementations due to corona. In the spring of 2020 a pandemic emerged, Covid-19, influencing the thesis. The pandemic made the group implement different measures to minimize it’s influence. For the whole risk analysis see attachment [K] 6.5.1. Administratively. Figure 37: Administrative implementations. 46.

(68) Bachelor, Spring 2020 Bachelor Thesis Automation. 7. Report. Testing and Reviews. This chapter covers all different tests and reviews the group has conducted. All changes that have been made due to testing and how this affected the end result.. 7.1. Design. In the process of reviewing and testing the system, it was discovered that multiple changes would benefit the final result. These are small things like variable naming, readability, structure of the code and GUI user-friendliness. 7.1.1. Human Machine Interface. As mentioned in chapter 3, section [3.3.4.2] the approach was to program three different GUI’s, one by each group member. All members made their own GUI design for both the freezer entrance and the bridge. This type of testing was done to find the most user-friendly GUI. The key to a successful HMI system requires a well-grounded definition and understanding of the operators. Our thoughts of characteristics for HMI after testing is explained underneath.. Figure 38: HMI Characteristics. 47.

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